Method of making iron molds or chills.



j GLA.' PHILLIPS, METHOD or ,MAKING IRON HOLDS OR 0111111.11..."v

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:Patented June 16, 1914.

- G. A. PHILLIPS. l METHOD 0F MAKING IRON MOLDS'OR GHILLS 4 ArrLIoATIo'N HLBD rmx. 24, 191s. 4 1,099,997. 'Patented June 16, 1914.

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f ATTY UNITED sTATEs PATENT onirica,

GERALD ALBERT rHILLirs, or eovENTEY, ENGLAND.

' METHOD or MAKING :mon MormsI on cintas.

specification of Letters Patent. Patented J une 16, 1914.

Original application led September 519'12', Serial No. 718,651. Divided and this application led February 2 4, 1913. Serial No. 750,274. i

To all whom t mayboncern:

Be it known that I, GERALD ALBERT PHIL- Lirs, of Speedwell WVorks, Sherborne street, in the city of Birmingham, Engla'nd, a subject o'f His Majesty the King. of Great Britain and Ireland, residing at Beechcote,

' Berkswell, Coventry, in the county of Varwick, England, have invented new and useful Improvements in the Method of Making Iron Molds or Chills, of which the following is a specification.

This invention has reference to a method of making those' iron molds, technically known as chills, -which are'made lin halves or otherwise in' two or more parts and are used in the manufacture of metallic bedsteads and cots and for other like uses and which are adapted to receive the ends or other parts of tubes or bars or othercastings or parts andto form inclosedor partly inclosed molds for the reception of molten cast iron which forms the chilled castings around said tubes, bars or parts to secure them together, as infthe case of what are known as flower chills in a bedstead rail or cot rail, or to form a top or other cast-l ing on a pillar, or a corner casting on a pillar, or other chill casting where required in the construction of a metallic bedstead or other article of metallic furniture or other vchilled iron casting. The halves or parts of the molds must match and fit accurately together and heretofore these irbn molds or chills have usually been madesas sand cast- 1 ings in halves whichhave been machined vwhere necessary and fitted together and trimmed up and finished by hand or machine labor,H the said half molds having intern ally the ornamentall or other shape of the required cast part of the bedstead or other t required chilled casting andv also having one.I or more cross. channels for the reception ofthe tube or tubes or other parts on towhich the chilled. casting is-to be made. The pres.

and this is particularly the case with ,flower chills as -in the simplest form` o fbedstead 'rail made with top., and bottom .tubes connected togethervby seven uprights,L fourteen pairs of these fi'wer chills al exactly alike arerequired to form thechilled castings connecting the endsof the of each pair being fixed by screws or other means to a frame at the proper distances apart and the other half of each pair being detachably` connected to these by -being hinged thereto or by chill hooks or by other suitable means.. a bedstead manufacturer has to keep many tous of these iron molds always in stock 4which have cost a very considerable sum to produce as every one of them has been lfitted together and finished by hand or machine labor. v

It is well known that in practice those portions of the iron molds or chills with which the molten iron comes into contact y and particularly the edges of the recesses in g the meeting faces ofthe iron molds or c hills soon become indistinct and incorrect in vshape. `This wear and rounding off of the jsaid edges of the'recesses in the meeting 'faces of the chill molds causes a rib or ribs upright tubes with the hoiizontals, one half It follows therefore that fon the casting formed therein where the Ahalves or parts of the chill molds meet. V'hen this wear has taken place to a serious extent the chill molds are useless except 'as `scrap iron or to be remelted.

.This 'invention comprises improvements 1j in the method of making the-said half or part iron molds or chills wherebytheir first 'cost is very materially reduced, they are formed with absolutely sharp edges to the recesses of their meeting faces, the cost of gtheir renewal is considerablyv reduced and l'moreover the weight 'ofthe iron molds or chills whichit will be necessary for a bedstead manufacturer to keep in'stock when =made` according to my invention will be re duced to a minimum.

YIn carrying out this invention these halves 4:or parts' ofthe said hollow iron molds or ing in contact with the 'molten metal and (as heretoforebut are made'as chilled iron fcastings in iron molds'or chills which for .distinction I call the master pattern and Afrom which any number ofthe said working chill molds can be made at avery smalll cost. Theworking chill molds are removably fixed iii the stocks on the stock frame in` such .a waythat they can very readily be -changed when required. Thus in making' rchills, which are liable to wear through com whichchills'or parts I call the working y chillI molds are not made as sand castings' forinstance 4a set of sayv fourteen pairs of 110 Itlieni'rom these master patterns which have been carefully finished the necessary number of halves of the working chill molds are cast,

'as chilled castings, of the proper shape to fit :in the'stocks or body portions ot the molds which are' shaped to receive them and are furnished with suitable means for holding the;working. chill molds in position, said stocks -or body portions of the molds being adapted ta be fixed to the stock i'rame.

' rl`he working chill half molds are interchangeable so that the same stocks or body portions of the molds will serve for holding different patterns of `working chill half molds which 'latter are very inexpensive owing to the very small amount of labor required 'to produce them. The weight of the iron molds or chills which it will be necessary for a bedstead manufacturer to keep in stock will be represented by the weight of the master patterns which will be very small in comparison with the many tons of iron molds which bedstead manufacturers have heretofore had to hold.

The figures of the accompanying drawings illustrate by way of example how the method according` to my invention is carried out in connection with the said flower chills for a metallic bedstead rail and they will serve to illustrate also how my invention can be applied to the chilled half or part molds for use in casting other chilled cast-- ings in the construction of metallic bedsteads or other articles of metallic furniture or other chilled iron castings.

'Figure 1y is a frontelevation of a stock frame` with fourteen stocks or molds fixed thereon and fitted with detachable working flower chill molds in accordance with this invention arranged for vcasting a bedstead rail; Fig. 2 is a side elevation of the saine;

' Fie. 3 shows se aaratel on a larO'e scale 'one of the stocks or bodies with-the two detach-v able and renewable worl'ing llower chill,

molds fixed therein; Fig. 4 isa sectional front elevation of the same; Fig. 5 is a plan of amold box complete with an interchange-` able master pattern; Fig.` G is a sectionalelevation of the same taken on line X X of Fie'. 5' Fi 7 is an inverted lalan of the b g4 1. arrangement shown in liigsg and 6; Fig.

S is a sectional elevation ofthe interchangeable master pattern; Fig. 9 is a front elevation vof one of the working chill half molds shown in Fig. 3; Fig. 1() is a sectional side elevation of the working chillhalf mold shown in Fig. 9; Fig. 11 is ay front elevation of another pattern of working half mold for .use with the stocks or bodies shown in Figs.

1, 2, 3, and 5; Fig. 12 is a sectional sido elevation of the same; Fig. 13 is a plan of a modified iiorm of mold box complete with a master pattern and is adapted to form two working chill hall' molds at one setting; Fig. 14 is a sectional elevation of the saine taken on line Y Y of Fig. 13; Fig. 15 is an inverted sectional plan ot'. the same taken on lineX X of Fig. 14; Fig. 1G is a sectional elevation of the interchangeable master pattern shown in Figs. 13, 1.4 and 15; 17 is a front elevation and Fig. 1S is a sectional side elevation of one of the working chill half molds which has been forn'ied in the master pattern shown in Figs. 13, 14, and 15;- Fig. 19 is a front elevation and Fig. 20 a sectional side elevation of the other working chill half mold has been formed" in the master terns shown in Figs. 13, 14, Fig. 21 is a sectional side elevation of one part of a two part sand molding box and half pattern, arranged for molding the master pattern shown in Fig. 1G; Fig. 22 is a plan of Fig. 2l but with the sand removed from the box; Fig. 23 is one half of the pattern for the same; Fig. 23 is a modified form of the pattern shown in Fig. 23; Fig. 24 shows the two parts of the two part molding box and sand mi ld closed with the pattern therein; Fig. 25 shows the saine two parts of the molding box separated and with a mold plate introduced between them to form the thick plate part of the interehangeablemaster pattern; Fig. 2G is aplan pat- of the same with the top part of the box removed; F ig. 27 is a front elevation of the interchangeable master pattern as it leaves the mold plate; Fig. 2S isa sectional elevation of the same; Fig. 29 is a front elevation of the interchangeable master pattern when finished with a small groove cut around the raised pattern part for the purpose here- I inatter described; Fig. 30 is a sectional elevation of Fig. 29; Fig. 31 is a sectional elevation of one of the halves of the workingl flower patterns in the form in which it leaves the master chill molds; Fig. 32 is a front 'elevation of the same andFig. 33 is asec' tional elevation of a portion of the same on an enlarged scale.

Referring first of all to Figs. 1,2, 3, and 4,. the two removable and renewable chilled cast iron working chillhalf molds are respectively marked 1 and 2, the working chill half mold 1 being recessed on its inner face at 3 to form the front of the required chill 1 of the bedstead rail where the vertical tubes 5 ofthe same meet the horizontal tubes 6 and 7 of the rail, the other working chill half mold 2 which matches the working chilll halt mold l has its recessed face S shaped to co1"- w-hich and 15;v4

respond with the back of the flower chill 4. Each of these working flower chill half molds also has the necessary groove 9 to receive` the vertical tube 5 and grooves 10 to receive the horizontal tube 6. Each lof the said working chill half molds 1, 2,` also has formed in its face a groove 11 along which the metal runs as it is poured into the mold.I These working chill half molds 1, 2, are respectively removably fixed in the two half stocks or body portions 12, 13, which are sand castings jointed together at one side by a joint pin 14 passing through knuckle lugs 15, `16, formed respectively on the two half stocks 12, 13, so that the half stocks can be turned on the joint pin 14 and opened apart as indicated by the dottedlines in F ig. 3. The preferred means of holding the working chill half molds 1, 2, in the corresponding halves o-f the stock is by the working chill half molds being made with somewhat of a dovetailed shape in cross section, see Fig. 3, with tapering sides 17, 18, 19, 20, which fit-in corresponding recesses in the half stocks 12, 13, and where they are respectively. secured by the two bolts 21, 22,

which pass through the half stocks 12, 13

and are furnished with nutsf23 on their outer ends so that when these are tightened up the heads 24 of the bolts bearing against. the tapering sides 18, 20,'securely hold the Working chill half molds 1, 2, in the dovetailed recesses.` The necessary number of these stocks fitted with the working chill half molds 1, 2, as above described are fixed to the stock frame (see Figs. 1 andy2). For a bedstead rail which has seven uprighttubes there are fourteen of these stocks with their corresponding working chill half molds seven being fixed to each of the horizontal flat bars 25, of the stock frames, said stocks being fixed thereto by studs. 27 passing through the bars. The other halves 12 Aof the seven stocks in a row are boltedrespeo tively to the two bars 28, 29, so that all those half'stocks in a row will be opened together,

each bar being furnished with a handle such Suitable cramps as 30, 31, for this purpose.` 32, 33, are employed at intervals jointed to the barsi`25, 26, and made with screws 34 to bear upon the bars 28, 29, and maintain the stocks closed while pouring.

1 will now describe theconstruction of i the .master patterns and the box like part in 55 which they are fixed to form the complete mold when casting the working chill half molds 1,- 2. A mold box fitted with a master pattern for this purpose is illustrated by patterns Y Figs: 5, G, and 7. This master p attern 35 is interchangeable and is made" with a part which has in relief the flower or other pattern part opparts which are required to form therecess'es in the working chill half The said interchangeable master are iron castings made like what is molds.

i known as a plate pattern that is, with a plate having projecting from its opposite .faces and in exact positions relatively to .in the surrounding mold box aforesaid which is by preference made in halves 38, 39,

hinged together by a pivot pin 40', and

formed with Vhandles 41 so as to be' readily opened4 apart and alsol provided with a suitable form of clip by which the two l halves can be retained in the closed position. The mold box is closed on one face l41a andy is made with a recess`42 in the other face in which the said plate .part of the master pattern 35 fits so that the cavity 43 between this plate part 35 and the closed face 41 of the mold box isadaptedto receive the molten iron,the ornamental recessed face 37 of which will be formed by the vpattern parts, 36 projecting from the interchangeable master pattern 35.

Before casting the other working chill half mold, the master pattern 35 has to be turned half around and fixed with its otherl face adjacent to the cavity 43 in the-interior Aof the mold box. The recess 42 in the mold box in which the master pattern 354is fixed is made with an 'internal straight edge 44 and all the master patterns are made with a corresponding straight edge v45 to correspond therewith, and againstsaid internal straight edge 44 the straight edge 45 of the master'pattern is forced by one or more set screws 46 or hther suitable means so that the said master patterns are always in their correct positions for casting. through which the moltenmetal is' poured is denoted by 47. While the above descrip; tion refers to a mold box for holding a mas# ter pattern by -which the master pattern has to be reversed for casting a corresponding pairof working chill fhalf molds, it will be obvious that the arrangement may be modihed as shown in Figs. 13 to 15 in which the mold box 48-is closed on both faces 49, 50,

.and the master pattern 36 is inserted inthe middle of the moldbox so as to form two cavities 51, 52, in which the respective halves of the working chillmoldsare cast. VTwo The `channel channels 53, 54, are'provided one -leading to the cavity 51 and one to the cavity 52. After "the master pattern 35 has. been fixed in the 'mold box theset screw 46 the molten To insure as aforesaid absolutely sharp or angular edges at the faces of the recessed portions of the workingchill half molds 1, 2, the masterpattern is grooved slightly all around the iiower or ornamental or other pattern parts 36 which project from the face of the plate part 35 of the master pattern as shown in Figs. 8, 16, and 30, so that when the halves of the working chill molds are cast as aforesaid the molten metal will run into this groove or grooves, and thereby form a rib or ribs 55 (Fig. 31) projectingtup above the faces of the working chill half molds all around and bordering the recess or recesses therein, as shown to an enlarged scale in Fig. 83. This rib or ribs 55 and if necessary a part of the face of the working chill half mold are then removed by grinding thereby leaving the edges of the faces of the recess or recesses absolutely sharp or angular as is necessary to insure that the halves of each pair of working chill molds lit properly to,- gether to prevent any ribs on the finished bedsteads or like castings which are cast in the complete working chill molds.

In forming the interchangeable master I pattern the ordinary lead flower chill Fig.

24, or other casting pattern which is made in halves as is usual is molded in sand in a two part box. In order to insure that the lead pattern shall occupy its proper position in the said two part box, one half 57 of the said pattern is detachably fixed on a plate 58 by dowel pins 59 or the like, this plate 58 having perforated ears through which the pegs 60 of the one half molding box 61 pass so that this half box 6l -isexactly located in relation to the half lead pattern 57 see Fig. 2l. lhen this part 6l of the box with the half-pattern 57 therein has been filled with sand and rammed in the usual way as shown in Fig. c2l, said half box 6l with the impression therein is removed from the plate 58,

.f after whichthe half pattern 57 is lifted off the plate and replaced in the half mold impression. The other half 56 of the lead pattern is then placed on the first half 57 and the other half molding box 62 is placed on the first half 6l which has been molded, as shown in Fig. 24, being finally filled with sand and rammed. This method insures the patternv coming in. its exact required position in the box. The two halves 61, 62, of the molding box are separated and between them is now introduced the plate 63 which isof the same thickness as the plate portion of the interchangeable master pattern 35.

The .said plate 63 has an aperture there through which corresponds with the outline shape of' the master-pattern. The said plate 63 is made with lugs 64 having holes which vfit on to the upstanding pegs 60 on theA bottom box 61, the upper half-62 of the box resting on the upper face of the perforated plate v63. The pegs`60` are by preference `made parallel and the half molding boxes are nicely tted togetherso that when the top box 62 i's placed on vthe perforated plate 68 the half mold in the top box will be exactly opposite the half mold in the bottom box. The casting is then poured, the box -opened and the master chill casting removed from the aperture 66 in the plate 63. The plate 63 is preferably made with its parts separable so that the master chill casting can be readily removed s uch for instance as by hinging thevtwo parts together at 65 or in any other suitable way. In order to allow for the expansion of the said intermediate plate 63 arising from its contact with the hot metal in the aperture 66 the holes in the lugs 64 of the plate 63 are so slotted or formed at 67 as to bear upon the outer'surfaces 68 of the pegs of the molding box to properly locate the intermediate )late 63 thereon, sufficient clearance being le t on the inner sides of the pegs to properly alloys7 for the expansion of the plate.

In order to make those working chill half which the top tube is curved instead of bcing a horizontal straight tube as in Fig. 1, n either-the lead pattern, 56, 57, or the master pattern, or both, has its print parts 69 for the -tubes or bars 6 made at the proper angles or positions to suit the Vworking chill half molds required, and`to effect this these print parts 69 may if desired be made adjustable in position to occupy various angles with the..

main portion of the chill as indicated for instance in Fig. 23 which shows a lead pattern like that shown in Fig. 23 but having its two side prints 70 for the top tube arranged inclined to the vertical. instead as in Fig. 23 being at right angles thereto.

lVhat I clain as my invention, and desire to secure by Letters Patent is l. A method of producing iron half or part chill molds wherein are cast parts of metallic bedsteads or other metallic furniture, consisting in forming an iron master pattern having grooves around the orna-` mentation or design, casting from said master pattern 1n a chill mold,work1ng half or part chill molds `having ribs thereon corre- .sponding to said grooves, grinding off said ribs so as to insure sharp edges to the recesses in the half or part molds thus en' abling them t9 fit accurately together to form a cavity wherein the filial castings are cast without fin or bur.

2. A method of making iron half or part molds adapted to lit or match together to form a cavity Awherein are cast the parts of inet-allie bedsteads or other metallic furniture, or other chill castings, whereby a iinished iron master pattern is formed by molding in a two part box a. cavity of the rcquil-cd shape, separating the parts of'said box and inserting a distance plate therebetween, running molten' metal into such cavity. and then casting in or against the nishcdiron master pattern thus formed the working half or part molds.4

A method of making iron half or part molds adapted to fit or match together to form a cavitywherein are cast the parts of metallic bedsteads or other metallic turniturc, or other chill castings, in which a half or part molding box and a half vor part original pattern are temporarily secured to a plate in delinite relation thereto, and sand is placed in said molding box and adapted to form a cavity corresponding with the said haltl or part original pattern, said box being inverted and the said plate removed; and in which the other hal'li` or part original pattern is temporarily fixed to the first halfin exact relative positionv thereto, the top molding box is placed on the bottom molding box and theA mold completed, the two molding boxes being separated and a distance plate inserted therebetween; and in which an iron master pattern is cast in the cavity thus formed and the working half or part molds are cast in or against the finished iron master pattern.

recesses and afterward grinding oil the said ribs.

A method of making sharp edges to the recessed parts of iron half or part molds adapted to fit or match together to form a cavity wherein are cast the parts of metallic bedsteads or other metallic furniture, or

other chill cast-ings, by forming a recess or recesses around the pattern part or parts of a finished master pat-tern, casting working half or part molds from said master pattern,

and grinding off the rib or ribs thus formed at the margins of the recessed parts of the working half or part molds.

In testimony whereof I have signed my name to this specification in the presence of two subscribing witnesses.

GERALD `ALBERT PHILLIPS.

y Witnesses:

BERTHA MATILDA DEELEY, CHARLES BoswoRTH Kerner. 

